The Risks of 'Over-Automating' the Workplace

Automation has become increasingly sought-after for modern, evolving workplaces across a spectrum of industries. Automation can be used to streamline manufacturing operations, manage routine office tasks with minimal human intervention, conduct risk assessments and boost efficiency, among a whole host of other advantages.

Given the scale of the global automation market ($193.87 billion in 2024 and poised to reach a $205.11 billion valuation in 2025), it’s fair to say that this will become more accessible and attainable for businesses sector-wide. It’s certainly not ambitious to suggest that automation is fundamentally transforming how companies currently operate and how they will in the near future.

However, as businesses embrace these innovations, it’s important to maintain a level head and avoid your organisation becoming ‘over-automated’. With the rise of the Internet of Things (IoT) and intelligent digital technologies, it’s easy to become too reliant on technology to the point where it becomes a health and safety concern. How is this possible and what can health and safety professionals do about it?

This short guide considers the potential risks of over-automation and how management can maintain appropriate human oversight and prevent it from escalating too far.

The Evolution of Workplace Automation

The journey toward automation began with mechanisation in traditional manufacturing but has since expanded dramatically across all sectors.

Today’s automated systems handle everything from complex assembly operations to routine administrative and financial tasks. The COVID-19 pandemic has accelerated this trend, with many organisations implementing automated solutions to maintain operations while reducing person-to-person contact.

There has been an outcry, however, for companies to exercise caution when deploying automation solutions, specifically to balance the benefits of increased efficiency and careful human supervision. Software, like humans, is not error-prone, meaning tasks – such as payroll processing, content creation, logistics, warehouse management, and others – can still be automated, but require careful supervision to ensure accuracy and validity.

Understanding Over-Automation

Over-automation occurs when businesses implement automation solutions and systems without careful consideration of human factors or without sufficient planning. While automation is widely touted as being an invariably safe and time- and resource-saving task, excessive reliance on automated systems can open the door to new vulnerabilities and risks.

Key Automation Risk Areas

Loss of Critical Human Judgement

While automated systems excel at handling routine tasks such as data entry and consolidation, labelling, and processing, they may struggle with nuanced situations requiring human judgement and discretion. For example, in manufacturing facilities, an over-reliance on automated quality control checks may not catch subtle defects or alterations that a watchful worker would spot immediately.

Skill Degradation

Automation runs the risk of making workers overly or entirely dependent on such systems. As such, their ability to perform important tasks manually may decrease over time. When systems fail or emergencies arise, manual intervention becomes necessary, and the need for flawless attention to detail becomes increasingly important.

Complexity and Integration Challenges

As organisations develop multiple layers of automation to their processes as they scale (for example, implementing smart building controls or automated logistics) the complexity of interconnected systems increases. Every new integration point creates potential safety risks, particularly if systems fail to seamlessly work together when required.

Sector-Specific Challenges

Manufacturing and Distribution

• Automated machinery requiring regular maintenance and safety checks
• Complex robotic systems that may not adequately account for human workers in shared spaces
• Automated warehouse systems that could create new ergonomic risks for remaining manual tasks

Office Environments

Automation and technology have opened up doors to make office operations (such as building management, digital workflows and task management) more efficient, but office managers must cultivate a sense of responsibility among the team to avoid complacency and lack of judgement.

For example, when moving offices (an admin-heavy task) artificial intelligence can be used to help organise data and consolidate communications, but scouring office space to rent and liaising with agents must be done individually and carefully, rather than via technology as a time-saving measure.

Healthcare and Critical Services

Automation in healthcare settings requires especially careful consideration and supervision, as errors could directly impact patient safety. Many pieces of equipment in healthcare facilities, laboratories, surgeries and clinics are automated to high standards, but a careful balance must be struck between using them autonomously to derive results and exercising sufficient control and lateral thinking.

Maintaining Effective Oversight When Automating Tasks

Best Practices for Safe Automation

• Risk Assessment
  Conduct thorough risk assessments before implementing new automated systems, considering both direct and indirect safety implications. Use the HSE risk assessment template as a framework to take influence from.
• Training and Competency
  Ensure workers maintain practical skills alongside their ability to operate automated systems. Regular refresher training helps prevent over-dependence on automation.
• Clear Procedures
  Establish clear procedures for when and how systems should be used and when human intervention should occur, particularly during system failures or emergencies.
• Regular Reviews
  Implement regular reviews of automated systems to ensure they continue to meet safety requirements and remain appropriate for current operational needs.

Strategies for Balanced Implementation

• Start with one or two pilot projects in controlled environments
• Carefully monitor outcomes before expanding implementation
• Maintain parallel manual processes during initial deployment
• Assess how effective automation is versus when not required
• Involve workers in the planning and implementation of automated systems
• Gather feedback on practical safety implicationsUse worker insights to identify potential risks and improvements
• Use worker insights to identify potential risks and improvements
• Acknowledge concerns and risk factors and develop relevant precautions as necessary
• Ensure automated systems complement rather than replace human capabilities
• Design systems with clear human oversight points
• Reinforce that automation is not an outright replacement for any staff if they express concerns
• Implement meaningful touchpoints where supervision is required before automation becomes too influential

Next Steps

While automation provides a wealth of efficiency and safety benefits, the risks of over-automation cannot be ignored. Businesses that focus on achieving a healthy balance of productivity, quality and satisfaction will find that automation can complement operations, rather than detract from them or pose obstacles.

Maintaining a measured dynamic in the implementation of automation systems will allow companies to harness their full benefits while avoiding the pitfalls of excessive automation.

The salient point is that automation should serve as a tool to enhance human efforts rather than a complete replacement for their real-world expertise, experience and knowledge.